Reduksi Waste Pada Produksi Conical Taper Head Bolt Dengan Metode Lean Six Sigma Sebagai Optimasi Produksi Fastener

Falah, Fajryansya Miftahul (2021) Reduksi Waste Pada Produksi Conical Taper Head Bolt Dengan Metode Lean Six Sigma Sebagai Optimasi Produksi Fastener. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Dalam dunia industri, Lean Six Sigma (LSS) merupakan salah satu tools yang sangat penting dalam proses improvement terutama di industri manufaktur. Metode LSS menggunakan tahapan Define, Measure, Analyze, Improve,dan Control (DMAIC) efektif dalam optimalisasi proses produksi, kualitas produk dan produktifitas. Bolt Company (BC) memproduksi sekitar 60% produk conical taper head bolt sehingga peneliti memilih produksi conical taper head bolt pada penelitian ini. BC baru mencapai angka produksi sebesar rata-rata 2300 set per bulan dari target produksi berjumlah 3000 set per bulan. Salah satu faktor yang mempengaruhi hasil produksi dan lead time produksi adalah waste. Sehingga, dengan mengurangi waste dapat meningkatkan dan mengoptimalkan proses produksi. BC mereduksi waste dengan LSS. Penelitian ini bertujuan untuk mengidentifikasi penyebab dari waste¸ menganalisis pengaruh waste, dan memberi alternatif perbaikan pada proses produksi conical taper head bolt dengan metode DMAIC menggunakan beberapa tools antara lain Analytical Hierarchy Process (AHP), Value Stream Mapping (VSM), analisa kapabilitas, 5 why’s dan FMEA. Hasil yang di dapat pada penelitian ini antara lain diketahui waste kritis adalah waiting dengan bobot rata-rata sebesar 0.292. dengan nilai inkonsistensi sebesar 0.077. Berdasarkan analisis Root Cause Analysis (RCA) diketahui bahwa kurang adanya evaluasi terhadap proses forging, blackening, dan heat treatment. Dengan rekomendasi perbaikan maka beberapa perubahan antara lain mengurangi waktu setting forging sebesar 20 % , meningkatkan kecepatan pemanasan blackening hingga 50 % dan mengurangi lead time pada proses heat treatment sebesar 50 %. ================================================================================================ Lean Six Sigma (LSS) is one of the essential tools in process improvement in the industrial world, especially in the manufacturing industry. The LSS method uses the Define, Measure, Analyze, Improve, and Control (DMAIC) stages to optimize the production process, product quality, and productivity. Bolt Company (BC) produces about 60% of conical taper head bolt products, so the researchers chose conical taper head bolt production in this study. BC has just achieved production figures of an average of 2300 sets per month from the production target of 3000 sets per month. One of the factors that affect production results and production lead time is waste. Thus, reducing waste can improve and optimize the production process. BC reduces waste with LSS. This study aims to identify the causes of waste, analyze the effects of waste, and provide alternative improvements to the conical taper head bolt production using the DMAIC method with the several tools such as Analytical Hierarchy Process (AHP), Value Stream Mapping (VSM), capability analysist, 5 why’s and FMEA. The results obtained in this study, among others, it is known that critical waste is waiting with an average weight of 0.292. with an inconsistency value of 0.077. Based on the analysis of Root Cause Analysis (RCA) it is known that there is a lack of evaluation of the forging, blackening, and heat treatment processes. With the recommendations for improvement, several changes include reducing the forging time setting by 20%, increasing the blackening heating speed by 50%, and reducing the lead time in the heat treatment process by 50%.

Item Type: Thesis (Masters)
Uncontrolled Keywords: Lean, Six Sigma, Waste, DMAIC
Subjects: T Technology > TS Manufactures > TS155 Production control. Production planning. Production management
Divisions: Faculty of Creative Design and Digital Business (CREABIZ) > Technology Management > 61101-(S2) Master Thesis
Depositing User: Fajryansya Miftahul Falah
Date Deposited: 02 Sep 2021 14:19
Last Modified: 02 Sep 2021 14:19
URI: https://repository.its.ac.id/id/eprint/91407

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